Method and apparatus for effecting transfer of reaction receptacles in an instrument for multi-step analytical procedures

ABSTRACT

Systems for effecting transfer of reaction receptacles between modules of an instrument for performing multi-step analytical procedures and for adjusting for variations in the positions of such modules includes a receptacle carrier supported on a track on which the carrier translates between different modules located adjacent to the track. The carrier includes a receptacle distribution head supported on a receptacle carrier carriage. The distribution head includes a receptacle moving mechanism adapted to move receptacles into and out of the distribution head and into and out of a module. The carriage is engaged with the track and adapted for translation along the track. Drive systems effect powered translation of the carriage, powered elevation and rotation of the distribution head, and powered movement of receptacles into and out of the distribution head. A transfer position locating system automatically determines a receptacle transfer position of the receptacle carrier with respect to each module.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is the National Stage pursuant to 35 U.S.C. §371 of PCTInternational Application No. PCT/US10/35143, which claims the benefitof U.S. Provisional Application No. 61/178,728, filed on May 15, 2009,the disclosure of each of which is incorporated by reference herein inits entirety.

FIELD OF THE INVENTION

The present invention relates to systems, methods and apparatus foreffecting transfer of reaction receptacles between modules of aninstrument for performing multi-step analytical procedures and forautomatically adjusting for variations in the positions of such modules.

BACKGROUND OF THE INVENTION

All documents referred to herein, or the indicated portions, are herebyincorporated by reference herein. No document, however, is admitted tobe prior art to the claimed subject matter.

Instruments having a variety of modules within which one or more stepsof a multi-step procedure are to be performed are known in the art. Achallenge in the design and operation of such instruments is devising away to efficiently transfer the receptacles within which reactions(e.g., chemical, biochemical or biological) take place (hereinafter“reaction receptacles”) between the different modules of the instrument.Modules within the instrument are often replaced or removed forservicing and then reinstalled, and thus the precise location of areceptacle transfer position can vary and is not known with completeaccuracy. Thus, the precise location at which any device or apparatusfor transferring reaction receptacles between modules must be positionedmay not be accurately known.

SUMMARY OF THE INVENTION

Aspects of the invention are embodied in an apparatus for transferringone or more receptacles between a plurality of receptacle-receivingstructures. The apparatus comprise a transport track, a receptaclecarrier, and a transfer position locating system. The transport trackhas opposed ends, and the receptacle-receiving structures are disposedat different locations adjacent to the transport track. The receptaclecarrier, which is operatively engaged with the transport track, isadapted to carry a receptacle and translate along the transport track ina first or second direction between the opposed ends of the track. Thereceptacle carrier is further adapted to selectively stop at a transferposition with respect to any of the receptacle-receiving structuresdisposed adjacent the transport track, and the receptacle carrierincludes a receptacle moving mechanism that is adapted to move areceptacle with respect to the receptacle carrier to move a receptacleinto the receptacle carrier, out of the receptacle carrier, oralternately into and out of the receptacle carrier. The transferposition locating system is adapted to automatically determine, for eachreceptacle-receiving structure, a location of a transfer position of thereceptacle carrier with respect to the receptacle-receiving structure toenable the receptacle carrier to transfer a receptacle between thereceptacle carrier and the receptacle-receiving structure.

According to other aspects of the invention, the transport trackcomprises a base portion and an upright backing portion and a guidetrack mounted on the base portion and a guide rail mounted to theupright portion. A portion of the receptacle carrier is engaged with theguide track and the guide rail. In certain embodiments, the transporttrack is linear, and in certain embodiments, the transport track issubstantially horizontal.

According to further aspects of the invention, the apparatus comprises acarrier translation system adapted to effect powered translation of thereceptacle carrier along the transport track, a carrier elevation systemadapted to move at least a portion of the receptacle carrier in atransverse direction with respect to the transport track, and/or acarrier rotation system adapted to rotate at least a portion of thereceptacle carrier about an axis of rotation.

In one embodiment, the carrier translation system comprises atranslation drive motor having an output shaft, a carrier drive beltcoupled to the receptacle carrier, and one or more pulleys supportingthe carrier drive belt. The carrier drive belt is coupled to the outputshaft of the translation drive motor so that rotation of the outputshaft is transmitted via the carrier drive belt into translation of thereceptacle carrier along the transport track.

In one embodiment, the apparatus includes encoder coupled to thetranslation drive motor for monitoring rotations of the output shaft.

In one embodiment, the apparatus includes a belt tensioner configured toimpart tension in the carrier drive belt.

In one embodiment, the apparatus comprises a carrier position sensorconfigured to detect when the receptacle carrier is in a specifiedposition on the transport track.

In one embodiment, the transport track is substantially horizontal, andthe carrier elevation system is adapted to move at least a portion ofthe receptacle carrier in a vertical direction with respect to thetransport track.

In one embodiment, the carrier elevation system comprises an elevationdrive motor having an output shaft, a drive screw shaft having alongitudinal axis and operatively coupled to the elevation drive motorfor powered rotation of the drive screw shaft, and an elevation blockcoupled to the drive screw shaft such that rotation of the drive screwshaft causes translation of the elevation block along the longitudinalaxis of the drive screw shaft, and at least a portion of the receptaclecarrier is carried on the elevation block.

In one embodiment, the apparatus comprises an encoder coupled to theelevation drive motor for monitoring rotations of the output shaft.

In one embodiment, the apparatus includes elevation position sensorconfigured to detect when at least a portion of the receptacle carrieris in a specified transverse distance from the transport track.

In one embodiment, the transport track is substantially horizontal andthe carrier rotation system is adapted to rotate the receptacle carrierabout an axis of rotation that is substantially vertical.

In one embodiment, the carrier rotation system includes a rotation drivemotor having an output shaft, a drive gear coupled to the output shaft,and a platform gear mounted so as to be rotatable about the axis ofrotation and coupled to the drive gear for powered rotation to theplatform gear, and at least a portion of the receptacle carrier iscarried on the platform gear. In one embodiment, the apparatus furtherincludes an encoder coupled to the rotation drive motor for monitoringrotations of the output shaft.

In one embodiment, the apparatus further includes a rotation positionsensor configured to detect when at least a portion of the receptaclecarrier is in a specified rotational position about the axis ofrotation.

In one embodiment, the receptacle moving mechanism includes a receptacleengagement device configured to releasably engage a receptacle to permitphysical manipulation of the engaged receptacle and a receptacle drivemotor having an output shaft coupled to the receptacle engagement devicefor effecting powered movement of the receptacle engagement device.

In one embodiment, the receptacle engagement device comprises a hook.

In one embodiment, the receptacle engagement device is carried on anengagement device carriage, and the receptacle moving mechanism furtherincludes a receptacle guide rail on which the engagement device carriageis translatably carried, a receptacle drive belt coupled to theengagement device carriage, and one or more pulleys supporting thereceptacle drive belt. The receptacle drive belt is coupled to theoutput shaft of the receptacle drive motor so that rotation of theoutput shaft is transmitted via the receptacle drive belt intotranslation of the engagement device carriage along the receptacle guiderail.

In one embodiment, the apparatus further includes an encoder coupled tothe receptacle drive motor for monitoring rotations of the output shaft.

In one embodiment, the apparatus further includes a belt tensionerconfigured to impart tension to the receptacle drive belt.

In one embodiment, the apparatus further includes an engagement deviceposition sensor configured to detect when the engagement device carriageis in a specified position on the receptacle guide rail.

In one embodiment, the receptacle carrier comprises a receptacle carriercarriage adapted to translate along the transport track and adistribution head supported by the receptacle carrier carriage andconfigured to receive and hold a receptacle, and the receptacle movingmechanism is disposed within the distribution head. In one embodiment, acarrier translation system is coupled to the receptacle carrier carriageand is adapted to effect powered translation of the receptacle carriercarriage along the transport track. In one embodiment, a carrierelevation system is coupled to the distribution head and is adapted tomove the distribution head relative to the receptacle carrier carriagein a direction transverse to the transport track. And in one embodimenta carrier rotation system is coupled to the distribution head and isadapted to rotate the distribution head relative to the receptaclecarrier carriage about an axis of rotation.

In one embodiment, the transfer position locating system includes aposition locator element associated with the receptacle carrier, one ormore signal generators adapted to generate signal data representative ofat least one of a position and an orientation of the receptacle carrier,and data storage configured to store signal data from the one or moresignal generators when the position locator element associated with thereceptacle carrier engages a position locator element associated withthe receptacle-receiving structure.

In one embodiment, the position locator element associated with thereceptacle carrier comprises a portion of the receptacle carrier thatphysically contacts a position locator element associated with thereceptacle-receiving structure.

In one embodiment, the position locator element associated with thereceptacle carrier comprises a receptacle engagement device coupled withthe receptacle moving mechanism and configured to releasably engage areceptacle to permit physical manipulation of the engaged receptacle.

In one embodiment, the apparatus further includes a controller in signalcommunication with the receptacle engagement device to capacitivelysense when the receptacle engagement device contacts the positionlocator element associated with the receptacle-receiving structure.

In an automated apparatus for transferring one or more receptaclesbetween a plurality of receptacle-receiving structures in which theapparatus includes a transport track with the receptacle-receivingstructures located adjacent to the transport track and a receptaclecarriage operatively engaged with the track and adapted to transport areceptacle along the track and insert a receptacle into or remove areceptacle from a receptacle-receiving structure disposed adjacent tothe track, aspects of the invention are embodied in a method forpositioning the receptacle carriage with respect to each of thereceptacle-receiving structures to enable the receptacle carriage totransfer a receptacle between the receptacle carriage and each of thereceptacle-receiving structures. The method comprises the steps of (a)moving the receptacle carriage along the track to an approximatelocation of one of the receptacle-receiving structures and then (b)moving the receptacle carriage with respect to the receptacle-receivingstructure in two or more directions until a position locator elementassociated with the receptacle carriage engages a position locatorelement associated with the receptacle-receiving structure. Engagementof the position locator element associated with the receptacle carriagewith the position locator element associated with thereceptacle-receiving structure identifies a transfer position of thereceptacle carriage with respect to the receptacle-receiving structureto enable the receptacle carriage to transfer a receptacle between thereceptacle carriage and the receptacle-receiving structure. In step (c),data relating to the transfer position for the receptacle-receivingstructure is stored. In step (d), steps (a)-(c) are repeated for each ofthe receptacle-receiving structures. In step (e), the receptaclecarriage is positioned with respect to each receptacle-receivingstructure to enable the receptacle carriage to transfer a receptaclebetween the receptacle carriage and the receptacle-receiving structureby retrieving the stored transfer position data associated with areceptacle-receiving structure and moving the receptacle carriage to thetransfer position defined by the retrieved transfer position data.

In one embodiment, moving the receptacle carriage with respect to thereceptacle-receiving structure in two or more directions includes movingthe receptacle carriage along the track and moving the receptaclecarriage in at least one direction transverse to the direction of thetrack.

In one embodiment, moving the receptacle carriage with respect to thereceptacle-receiving structure in two or more directions furthercomprises rotating the receptacle carriage about an axis of rotation andmoving a receptacle-engaging element of the receptacle carriage in aradial direction with respect to the axis of rotation.

In one embodiment, the receptacle carriage is moved with respect to thereceptacle-receiving structure until a portion of the receptaclecarriage physically contacts a portion of the receptacle-receivingstructure.

In one embodiment, physical contact of a portion of the receptaclecarriage with a portion of the receptacle-receiving structure isdetermined by capacitive sensing.

Aspects of the invention are embodied in an apparatus for transferringone or more receptacles between a plurality of receptacle-receivingstructures, one or more of the receptacle receiving structures includinga receptacle transfer portal through which a receptacle is placed intoor removed from the receptacle-receiving structure and a door disposedover the receptacle transfer portal. The apparatus comprises areceptacle carriage and a carriage positioning system. The receptaclecarriage is adapted to carry a receptacle and to selectively stop at atransfer position with respect to any of the receptacle-receivingstructures. The receptacle carriage includes a receptacle movingmechanism adapted to move a receptacle with respect to the receptaclecarriage to move a receptacle into the receptacle carriage, move areceptacle out of the receptacle carriage, or alternately move areceptacle into and out of the receptacle carriage. A portion of thereceptacle carriage is adapted to engage a door of areceptacle-receiving structure and open the door upon performance of apredetermined movement of the receptacle carriage with respect to thereceptacle-receiving structure. The carriage positioning system isadapted to automatically position the receptacle carriage so that aportion of the receptacle carriage engages a door of a selected one ofthe receptacle-receiving structures and to effect the predeterminedmovement of the receptacle carriage to open the door.

In one embodiment, the apparatus further includes a transfer positionlocating system adapted to automatically determine, for eachreceptacle-receiving structure, a location of a transfer position of thereceptacle carriage with respect to the receptacle-receiving structureto enable the receptacle carriage to engage a door of eachreceptacle-receiving structure.

In one embodiment, the transfer position locating system comprises aposition locator element associated with the receptacle carriage, one ormore signal generators adapted to generate signal data representative ofat least one of a position and an orientation of the receptaclecarriage, and data storage configured to store signal data from the oneor more signal generators when the position locator element associatedwith the receptacle carriage engages a position locator elementassociated with the receptacle-receiving structure.

In one embodiment, the portion of the receptacle carriage adapted toengage the door of the receptacle-receiving structure comprises abracket projecting from the receptacle carriage and configured to engageby contact an actuating element extending from the door.

In one embodiment, a portion of the receptacle carriage is adapted toengage a door of a receptacle-receiving structure and open the door uponperformance of a lateral movement of the receptacle carriage to move thedoor laterally from a closed position to an open position with respectto the receptacle transport portal.

In one embodiment, a portion of the receptacle carriage is adapted toremain engaged with the door of the receptacle-receiving structure,after the predetermined movement of the receptacle carriage, to hold thedoor in an open position with respect to the receptacle transport portalwhile the receptacle carriage moves a receptacle through the receptacletransport portal.

In an automated apparatus for transferring one or more receptaclesbetween a plurality of receptacle-receiving structures, wherein theapparatus includes a receptacle carriage adapted to transport areceptacle relative to the receptacle-receiving structures and insert areceptacle into or remove a receptacle from a receptacle-receivingstructure, one or more of the receptacle receiving structures includinga receptacle transfer portal through which a receptacle is placed intoor removed from the receptacle-receiving structure and a door disposedover the receptacle transfer portal, aspects of the invention areembodied in a method for opening a door over a receptacle transferportal using the receptacle carriage. The method comprises the step ofpositioning the receptacle carriage so that a portion of the receptaclecarriage that is adapted to engage a door of a receptacle-receivingstructure and to open the door upon performance of a predeterminedmovement of the receptacle carriage with respect to thereceptacle-receiving structure engages a door of one of thereceptacle-receiving structures. Next the predetermined movement of thereceptacle carriage is effected to open the door.

In one embodiment, positioning the receptacle carriage comprises thesteps of (a) moving the receptacle carriage to an approximate locationof one of the receptacle-receiving structures and (b) moving thereceptacle carriage with respect to the receptacle-receiving structurein two or more directions until a position locator element associatedwith the receptacle carriage engages a position locator elementassociated with the receptacle-receiving structure. Engagement of theposition locator element associated with the receptacle carriage withthe position locator element associated with the receptacle-receivingstructure identifies a transfer position of the receptacle carriage withrespect to the receptacle-receiving structure to enable the receptaclecarriage to engage a door of the receptacle-receiving structure. In step(c), data relating to the transfer position for the receptacle-receivingstructure is stored. In step (d), steps (a)-(c) are repeated for each ofthe receptacle-receiving structures. And in step (e), the receptaclecarriage is positioned with respect to each receptacle-receivingstructure to enable the receptacle carriage to engage the door of eachreceptacle carriage by retrieving the stored transfer position dataassociated with a receptacle-receiving structure and moving thereceptacle carriage to the transfer position defined by the retrievedtransfer position data.

In one embodiment, the portion of the receptacle carriage adapted toengage the door of the receptacle-receiving structure comprises abracket projecting from the receptacle carriage and configured to engageby contact an actuating element extending from the door, and positioningthe receptacle carriage comprises moving the receptacle carriage to aposition at which the bracket engages the actuating element of the door.

In one embodiment, effecting the predetermined movement comprises movingthe receptacle carriage laterally to move the door laterally from aclosed position to an open position with respect to the receptacletransport portal.

In one embodiment, the method further includes, after effecting thepredetermined movement, maintaining a position of the receptaclecarriage engaged with the door of the receptacle-receiving structure tohold the door in an open position with respect to the receptacletransport portal while the receptacle carriage moves a receptaclethrough the receptacle transport portal.

Other features and characteristics of the present invention, as well asthe methods of operation, functions of related elements of structure andthe combination of parts, and economies of manufacture, will become moreapparent upon consideration of the following description and theappended claims with reference to the accompanying drawings, all ofwhich form a part of this specification, wherein like reference numeralsdesignate corresponding parts in the various figures.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an analyzer including various modulesconfigured to receive one or more reaction receptacles and within eachof which is performed one or more steps of a molecular assay, or otherbiological or chemical process, and a receptacle transfer apparatus fortransferring reaction receptacles between the various modules and insertreaction receptacles into and removing reaction receptacles from themodules.

FIG. 2 is a perspective view of a reaction receptacle in the form of amultiple receptacle device employed in combination with an apparatusembodying aspects of the present invention.

FIG. 3 is an enlarged bottom view of a portion of the multiplereceptacle device, viewed in the direction of arrow “60” in FIG. 2.

FIG. 4 is a perspective view of a receptacle transfer apparatus in theform of a receptacle distributor embodying aspects of the presentinvention.

FIG. 5 is a perspective view of an opposite side of the receptacledistributor from that shown in FIG. 4.

FIG. 6 is an enlarged partial perspective view of the receptacle carrierassembly of the receptacle distributor.

FIG. 7 is an enlarged partial perspective view of a proximal end of atrack assembly of the receptacle distributor showing a belt tensionerwith pulley and spring.

FIG. 8 is an enlarged partial perspective view of a distal end of thetrack assembly of the receptacle distributor showing a home positionsensor and carrier translation belt drive wheel.

FIG. 9 is an enlarged partial perspective view of the receptacle carrierassembly showing a receptacle distribution head and a portion of acarrier assembly carriage.

FIG. 10 is a perspective view of a Z-axis drive system of the carrierassembly carriage of the receptacle carrier assembly.

FIG. 11 is a perspective view, partially in cross-section along the line11-11, of the Z-axis drive system of FIG. 10.

FIG. 12 is a partial perspective view of a carrier rotation system (0drive system) of the carrier assembly carriage of the receptacle carrierassembly.

FIG. 13 is an enlarged partial perspective view of a portion of thecarrier rotation system.

FIG. 14 is a perspective view of the receptacle distribution head and ahook actuator system in an extended position.

FIG. 15 is a perspective view of the receptacle distribution head andthe hook actuator system in a retracted position and a multiplereceptacle device inside the distribution head.

FIG. 16 is a perspective view of the receptacle distribution head from aside opposite that shown in FIGS. 14 and 15.

FIG. 17 is a partial cross-sectional perspective view of thedistribution head along the line 17-17 in FIG. 16.

FIG. 18 is an end view of the receptacle distribution head.

FIG. 19 is a partial perspective view of the incubator and a receptacletransport mechanism adapted to place reaction receptacles into theincubator and remove reaction receptacles from the incubator.

FIG. 20 is a schematic block diagram of the control architecture of thereceptacle distributor.

FIG. 21 is a flow chart illustrating the steps of a process by which thereceptacle distributor automatically determines the coordinates of areceptacle transfer position with respect to each module of theinstrument.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Overview

An analyzer in which the method and apparatus of the present inventionmay be implemented is shown schematically in plan view and designated byreference number 100 in FIG. 1. The analyzer 100 includes variousmodules configured to receive one or more reaction receptacles(described in more detail below) within each of which is performed oneor more steps of a multi-step analytical process, such as a nucleic acidtest (NAT), or other chemical, biochemical or biological process. Themodules of the analyzer 100 constitute receptacle-receiving structuresconfigured to receive and hold one or more reaction receptacles. Thepresent invention embodies methods and apparatus for transferringreaction receptacles between the various modules of the analyzer 100 andfor inserting reaction receptacles into and removing reactionreceptacles from the modules.

In one embodiment, an exemplary analyzer in which the present inventionmay be implemented may include a receptacle input module 102 includingstructure for receiving and holding one or more empty reactionreceptacles prior to the receptacles being used for performing achemical, biological, or other multi-step analytical process. Thereceptacle input module 102 may comprise a drawer holding a plurality ofreceptacles and may include a receptacle feeding apparatus for movingreceptacles, e.g., one at a time, into a receptacle pick-up position.

Analyzer 100 may further include load stations 104, 106, 108 configuredto receive a reaction receptacle and within which one or more materialsmay be added to the receptacles, including sample material and variousreaction reagents. In an implementation where the analyzer 100 comprisesa platform for performing NATs, reaction reagents may comprise targetcapture reagents, nucleic acid amplification reagents, and nucleic aciddetection reagents.

Analyzer 100 may further comprise temperature ramping stations 110configured to hold one or more reaction receptacles in an environmentthat is maintained at higher than ambient temperatures so as to raisethe temperature of the contents of the receptacles. Analyzer 100 mayfurther include one or more incubators. The illustrated analyzer 100includes three incubators 112, 114, 116, each of which is configured toreceive a plurality of reaction receptacles and maintain the receptaclesin an elevated temperature environment.

Also, in an implementation in which the analyzer 100 comprises aplatform for performing NATs, the analyzer may include sample-processingmodules, such as magnetic separation wash stations 118, 120 adapted toseparate or isolate an analyte of interest (e.g., a target nucleic acid)bound to a magnetically-responsive target capture material from theremaining contents of the receptacle. Analyzer 100 may further includechilling modules 122 adapted to receive one or more reaction receptaclesand hold the receptacles in a lower than ambient temperature environmentso as to reduce the temperature of the contents of the receptacles.Finally, analyzer 100 may include a detector module 124 adapted toreceive a reaction receptacle and detect a signal (e.g., an opticalsignal) emitted by the contents of the reaction receptacle. In oneimplementation, detector module 124 may comprise a luminometer fordetecting luminescent signals emitted by the contents of a receptacle ora fluorometer for detecting fluorescent emissions.

The analyzer 100 further includes a receptacle transfer apparatus,which, in the illustrated embodiment, comprises a receptacle distributor300, embodying aspects of the present invention. Each of the modules ofthe analyzer 100 includes a receptacle transfer portal through whichreceptacles are inserted into or removed from the respective modules.Each module may or may not include an openable door covering itsreceptacle portal. The receptacle distributor 300 is configured to movereceptacles between the various modules and retrieve receptacles fromthe modules and deposit receptacles into the modules. More specifically,the receptacle distributor 300 includes a receptacle distribution head312 configured to move in an X direction along a transport trackassembly 458, rotate in a theta (Θ) direction, and move receptacles inan R direction into and out of the receptacle distribution head 312 andone of the modules of analyzer 100.

In operation, the receptacle distribution head 312 moves in the Xdirection along the transport track assembly 458 to a transfer positionwith respect to one of the modules. The distribution head then rotatesin the Θ direction to place the distribution head in a receptacletransfer orientation with respect to the receptacle transfer portal ofthe module. A receptacle moving mechanism moves in an R direction withrespect to the distribution head to move a receptacle from thedistribution head into the module or to retrieve a receptacle from themodule into the distribution head. As will be described in furtherdetail below, the receptacle distributor further includes means foreffecting vertical (Z-axis, normal to the page of FIG. 1) positionadjustment of the distribution head to accommodate variations invertical position of the receptacle transfer portals of the variousmodules due to, for example, manufacturing and installation tolerances.Also, as will be described in further detail below, the receptacledistributor 300 includes a “self-teaching” system for automaticallyidentifying the correct X, Z, and R transfer positions with respect tothe receptacle transfer portal of each module. Finally, the receptacledistributor 300 may include structural elements and associated controllogic for opening a door that is covering a receptacle transfer portalbefore inserting a reaction receptacle into the module or removing thereaction receptacle from the module.

Multiple Receptacle Device

As shown in FIG. 2, a reaction receptacle in the form of a multiplereceptacle device (“MRD”) 160 that can be used in conjunction with thepresent invention comprises a plurality of individual receptacle vessels162, five in the illustrated embodiment. Other types of receptacledevices can be used in conjunction with the invention, including devicescomprising a single, individual receptacle vessel. In the illustratedembodiment, the receptacle vessels 162 are in the form of cylindricaltubes with open top ends and closed bottom ends and are connected to oneanother by a connecting rib structure 164 which defines a downwardlyfacing shoulder extending longitudinally along either side of the MRD160. In the illustrated embodiment of the MRD 160, all of the receptaclevessels 162 are substantially identical in size and shape. In otherembodiments, the MRD may include receptacle vessels of varying size,shape, and type and which can be configured for use with the presentinvention (e.g., microtiter plates).

In one embodiment, the MRD 160, or other receptacle, is formed frominjection molded polypropylene, such as that sold by MontellPolyolefins, of Wilmington, Del., product number PD701NW or by Huntsman,product number P5M6K-048.

An arcuate shield structure 169 is provided at one end of the MRD 160.An MRD manipulating structure 166 extends from the shield structure 169.The manipulating structure is adapted to be engaged by the receptacledistributor 300 for moving the MRD 160 between different locations ofthe analyzer 100. MRD manipulating structure 166 comprises a laterallyextending plate 168 extending from shield structure 169 with avertically extending piece 167 on the opposite end of the plate 168. Agusset wall 165 extends downwardly from lateral plate 168 between shieldstructure 169 and vertical piece 167.

As shown in FIG. 3, the shield structure 169 and vertical piece 167 havemutually facing convex surfaces. The MRD 160 may be engaged by thedistributor 300, by moving an engaging member (e.g., a hook) laterally(in the direction “A” in FIG. 2) into the space between the shieldstructure 169 and the vertical piece 167. The convex surfaces of theshield structure 169 and vertical piece 167 provide for wider points ofentry for an engaging member undergoing a lateral relative motion intothe space.

A label-receiving structure 174 having a flat label-receiving surface175 is provided on an end of the MRD 160 opposite the shield structure169 and MRD manipulating structure 166. Human and/or machine-readablelabels, such as scannable bar codes, can be placed on the surface 175 toprovide identifying and/or instructional information on the MRD 160. TheMRD 160 may also include tiplet holding structures 176 adjacent the openmouth of each respective receptacle vessel 162. Each tiplet holdingstructure 176 provides a cylindrical orifice within which is received aconduit, such as contact-limiting tiplet 170, that is adapted to beplaced onto the end of an aspirating tube (no shown). Each holdingstructure 176 is constructed and arranged to frictionally receive atiplet 170 in a manner that prevents the tiplet 170 from falling out ofthe holding structure 176 when the MRD 160 is inverted, but permits thetiplet 170 to be removed from the holding structure 176 when engaged bya pipette. Further details regarding this embodiment of the MRD 160 maybe found in U.S. Pat. No. 6,086,827.

Receptacle Distributor

As shown in FIGS. 4-6, a receptacle transfer apparatus in the form of areceptacle distributor 300 comprises a receptacle carrier assembly 310which translates along a transport track assembly 458 in an “X”direction” under the power of an X-translation system (described below).The receptacle carrier assembly 310 includes a receptacle distributionhead 312 configured to carry a reaction receptacle, such as an MRD 160,supported on a carrier assembly carriage 400 constructed and arranged toeffect Z-axis translation and Θ rotation of the distribution head 312 aswill be described below. In the illustrated embodiment, the trackassembly 458 is linear (i.e., straight) and substantially horizontal,but it can be appreciated that aspects of the present invention can beincorporated in, and the scope of the invention encompasses, areceptacle distributor having a track assembly that is non-linear (i.e.,at least partially curved) and/or non-horizontal (i.e., at least aportion of the track assembly is inclined or vertical).

In the illustrated embodiment, track assembly 458 comprises a generally“L” shaped channel 460 comprising a base portion 462—orientedsubstantially horizontally in the illustrated embodiment—and an uprightbacking 464 extending in an upright manner—oriented substantiallyvertically in the illustrated embodiment—from one edge of the horizontalbase 462. A stiffening flange 474 extends upright from an edge of thebase portion 462 opposite the upright backing 464, and a stiffeningflange 472 extends laterally from an upper edge of the upright backing464. A guide rail 480 is mounted to the upright backing 464 and extendsin a parallel orientation with respect to the base portion 462. A cableguide track 486 is mounted to the base portion 462.

An X-translation system 500 comprises a drive, or transmission, belt 504trained over a driven pulley 506 disposed on one side of the uprightbacking 464 at a distal end 476 of the channel 460 and over an idlerpulley 516 disposed on the same side of the upright backing 464 at aproximal end 478 of the channel 460. Driven pulley 506 is operativelycoupled to a carrier translation motor 502 mounted to an opposite sideof the upright backing 464 (See FIG. 5). Carrier translation motor 502is preferably a stepper motor with an optical encoder attached to thedrive shaft coupled to the driven pulley 506. A suitable motor includesNanotec model no. ST5918L6404-KSTR-E1, and a suitable encoder includesHEDSS model no. HKT2204-702C-200B-5E. Drive belt 504 is preferably aKevlar belt with a 5 mm module (T5) cut to length.

As shown in FIG. 5, the drive belt 504 is attached to the carrierassembly 310 by a bracket 508 which fixes the belt 504 to one side ofthe carriage 400. An access opening 466 in the upright backing 464provides access to the bracket 508 and facilitates attachment of thecarrier assembly 310 to the drive belt 504.

Referring to FIG. 7, which shows a partial perspective view of theproximal end 478 of track assembly 458, the drive belt 504 is preferablyequipped with a belt tensioner 510. Belt tensioner 510 comprises asliding pulley mount 512, on which is mounted the idler pulley 516, anda spring 514. Spring 514 is disposed within an opening 468 formed in theupright backing 464 of the channel 460 and is compressed between an edgeof the opening 468 and a portion of the sliding pulley mount 512disposed within or adjacent to the opening 468. Sliding pulley mount 512includes a transverse pin 518 extending into a longitudinally-extendingslot 470 formed in the upright backing 464. Screws 520 extend throughthe sliding pulley mount 468 and into slotted openings formed in theupright backing 464. During assembly of the receptacle distributor 300,the drive belt 504 is placed on the driven pulley 506 of the carriertranslation motor 502 at the distal end 476 of the transport trackassembly 458. The sliding pulley mount 512 and the idler pulley 516 arepushed against the spring 514 toward the driven pulley 506 (as far asthe length of slot 470 within which pin 518 extends will permit), andthe sliding pulley mount 512 is fixed with screws 520 to permit thedrive belt 504 to be placed onto the idler pulley 516 at the proximalend 478 of the transport track assembly 458. The screws 520 of the belttensioner 510 are then loosened, and the drive belt 504 tension ismaintained by the spring 514, which urges the sliding pulley mount 512and pulley 516 in a direction away from the driven pulley 506. Thelocation of the pulley 516 is then fixed by screws 520 after the spring514 effects proper tension on the drive belt 504.

The distribution head 312 of the carrier assembly 310 is carried alongthe transport track assembly 458 by the carrier assembly carriage 400.The carrier assembly carriage 400 engages the guide rail 480, andtranslates along the transport track assembly 458. Rubber bumpers 482,484 may be provided at opposite ends of the guide rail 480 to absorbcontact by the carriage 400. Movement of the carrier assembly carriage400 along the guide rail 480 is effected by the drive belt 504. When thecarrier translation motor 502 rotates the driven pulley in acounter-clockwise fashion, the carrier assembly 310 is moved in a firstX direction (to the left in the illustrated embodiment) towards theproximal end 478 of transport track assembly 458. Similarly, when thecarrier translation motor 502 rotates driven pulley 506 in a clockwisefashion, the carrier assembly 310 translates in a second X direction (tothe right in the illustrated embodiment) towards the distal end 476 oftransport track 458 assembly.

In one embodiment, the carrier assembly 310 has a linear travel of 750mm. The diameter of the driven pulley 506 is preferably 21.45 mm,providing a resolution of 0.337 mm/step of the carrier translation motor502 in full step mode. The encoder of motor 502 offers a resolution of200 counts/revolution (A-B signals) resulting in a quadrupled resolutionof 800 counts/revolution.

As shown in FIGS. 5 and 8, which shows a partial perspective view of thedistal end 476 of track assembly 458, an X-drive printed circuit board(“PCB”) 522 for the carrier translation motor 502 is mounted on theupright backing 464 of the channel 460 adjacent to the carriertranslation motor 502. X-drive PCB 522 is electronically coupled to thecarrier assembly carriage 400 by a flexible cable 524. Cable guide 486guides the flexible cable 524 as the carrier assembly carriage 400translates to various positions along the transport track assembly 458.Strain reliefs 526, 528 secure the flexible cable 524 to the carrierassembly carriage 400 and to the transport track assembly 458,respectively.

As shown in FIG. 8, a “home” sensor 530, mounted on the X-drive PCB 522,detects when the carrier assembly 310 is at the distal end 476 of thetransport track assembly 458. Sensor 530 is preferably a slotted opticalsensor which is “tripped” when a structural element (e.g., a rod orflag) projecting from the carrier assembly carriage 400 disrupts thesensor. A suitable sensor includes OPTEK model no. OPB 900W55.

While X-axis translation of the carrier assembly 310 and distributionhead 312 along the track assembly 458 is effected by the motor 502 anddriven pulley 506 rotating the drive belt 504 attached to the carrierassembly carriage 400, transverse, or Z-axis, translation of thedistribution head 312 with respect to the track assembly 458 is effectedby a Z-axis drive system 402 housed within the carrier assembly carriage400. Referring to FIGS. 10 and 11, which show the Z-axis drive system402 that is housed in the carrier assembly carriage 400, the Z-axisdrive system 402 includes a Z-drive stepper motor 404, mounted to amotor mount 410, and an elevation block 412 which is operatively coupledto the motor 404 by means of a ball screw 406 engaged with a ball nut408 that is attached to a lower panel 416 of a box chamber portion 418of the elevation block 412. A suitable motor includes Nanotec model no.ST4118M1404-B. The distribution head 312 is supported on the elevationblock 412 and translates transversely up or down under the power of themotor 404 via rotation of the ball screw 406 engaged with the ball nut408. The elevation block 412 is supported for transverse (vertical inthe illustrated embodiment) movement with respect to the track assembly458 by a linear guide 424 comprising a guide rail 425, attached to avertical outer wall 418 of the box chamber portion 414 of the elevationblock 412, and a linear bearing 427 (e.g., an IGUS linear guidebearing), attached to a portion of a carriage housing wall 401 of thecarriage 400.

As shown in FIG. 11, a Z “home” position sensor 428 is mounted to aZ-drive PCB 426 and signals the lower most position of the elevationblock 412. The Z-home position sensor 428 is preferably a slottedoptical sensor which is “tripped” when a home flag 419 projecting fromthe box chamber portion 414 of the elevation block 412 disrupts thesensor 428. A suitable sensor includes a Sharp model no. GP1S94. Anangular encoder is comprised of two slotted optical sensors (not shown)on the Z-drive printed circuit board 426 together with a slotted disk432 which rotates with the shaft of the motor. Suitable sensor includeSharp model no. GP1S94. The theoretical resolution of the encoder ispreferably 0.04 mm.

Rotation of the distribution head 312 is effected by a Θ drive systemthat is also located within the carrier assembly carriage 400 andindicated generally by reference number 440 in FIGS. 9, 12, and 13. TheΘ drive system comprises carrier rotation motor 442 mounted on a motormount portion 420 of the elevation block 412, a platform gear 446 onwhich the distribution head 312 is carried and which is rotatablymounted on a shaft (not shown) supported within a bearing 449 (see alsoFIG. 11) pressed into a bearing block portion 422 of the elevation block412, and drive gear 444 mounted on the output shaft of motor 442.Bearing 449 and the shaft supported therein define an axis of rotationof the distribution head 312 corresponding to the longitudinal axis ofthe bearing 449. A suitable motor includes Nanotec model no.ST4118S1404-KSTR-E1. A rotational encoder 441 is coupled to the motor442. A suitable encoder includes HEDSS model no. HKT2204-702C-200B-5E.Drive gear 444 is operatively engaged with platform gear 446, forexample, by mating gear teeth. As can be appreciated from FIGS. 12 and13, rotation of the drive gear 444 by motor 442 causes a correspondingrotation of platform gear 446, which in turn rotates the distributionhead 312 in the Θ direction.

In the illustrated embodiment, track assembly 458 is substantiallyhorizontal, and the axis of rotation defined by the longitudinal axis ofthe bearing 449 is substantially vertical and normal to the trackassembly 458. It can be appreciated, however, that aspects of thepresent invention can be incorporated in, and the scope of the inventionencompasses, a distribution head that is rotatable on an axis ofrotation that is not necessarily vertical or normal to the trackassembly 458.

Distribution head 312 is operatively coupled for electroniccommunication with the carriage 400 by flexible cable 452, which isconnected at one end to z-drive PCB 426 attached to the carriage 400 andat its opposite end to a hook extension PCB 362 attached to thedistribution head 312 (see FIG. 9). Strain reliefs 454 and 456 securethe flexible cable 452 to the carrier assembly carriage 400 and to thedistribution head 312, respectively. As shown in FIGS. 12 and 13, anintermediate portion of the cable 452 is loosely coiled around the axisof rotation of the platform gear 446 to accommodate rotation of thedistribution head 312

As shown in FIGS. 9 and 13, the rotational position of the distributionhead 312 is determined by means of a Θ home sensor 450, preferably aslotted optical sensor. A suitable sensor includes OPTEK model no. OPB900W55. An aperture 448 is formed through the platform gear 446. Whenthe platform gear 446 rotates to the home position, sensor 450encounters the aperture 448, thereby tripping the sensor 450 (byun-blocking the sensor beam) to indicate the home rotational position ofthe platform gear 446, and thus the distribution head 312. In oneembodiment, the home position of the distributor head 312 corresponds toalignment of the distribution head 312 with the longitudinal (X) axis ofthe track assembly 458, and is the preferred orientation of thedistributor head 312 when the carrier assembly 310 is translating alongthe track assembly 458.

The distribution head 312 for the receptacle vessels 162 preferablyrotates 280° to reach any direction where the receptacle transferportals of analyzer modules are located on the automated analyzer. Therotation angle of the distribution head is limited to 280° by amechanical stop, such as the screw 445 protruding through the bottom ofgear 446 in FIG. 12 that will hit the block 412 to limit rotation.

The carrier rotation motor 442 is preferably a stepper motor with arotational encoder 441 attached to the motor shaft. The resolution forthe rotational encoder is preferably 200 counts/revolution (A-Bsignals), resulting in a quadrupled resolution of 800 counts/rev. Thegear ratio between platform gear 446 and drive gear 444 is preferably 8to 1. In full step mode, the angular steps for the drive system Θ arepreferably 0.225°. Motor 442 is preferably mounted in slots formed inthe motor mount portion 420 of the elevation block 412 and is pushedtowards the platform gear 446 during production to avoid slack.

Details of the distribution head 312 are shown in FIGS. 14-18.Distribution head 312 includes a distribution frame 314 that is attachedto the platform gear 446 of the theta drive system 440. A side panel 315is attached to one side of the distribution head frame 314. Side panel315 may be transparent so that the interior of the distribution head 312is visible. Distribution head 312 further includes a receptacle hook 318configured to engage the manipulating structure 166 of an MRD 160.Devices other than a hook for engaging the receptacle and enablingphysical manipulation of the engaged receptacle are encompassed withinthe scope of the invention.

A hook actuator system 316 effects linear translation (in the Rdirection) of the receptacle hook 318 between an extended position, asshown in FIG. 14, and a retracted position, as shown in FIG. 15. Thehook actuator system 316 includes a hook carriage 320 to which thereceptacle hook 318 is attached. A drive belt 344 is attached to thehook carriage 320 by a screw and bracket indicated at 322. Drive belt344 is carried on a drive wheel 334 and idler wheels 336, 338, 340, 342.Idler wheels 340 and 342 are attached to a fixed idler wheel bracket358, and idler wheel 338 is attached to an upper portion of a doorengagement bracket 360 exterior to panel 315.

Door engagement bracket 360 may be provided for opening a door coveringa receptacle transfer portal of a module of the analyzer 100. The door,which may be a pivoting, sliding, or rotating door, will include an armor other projection depending from a portion of the door. Thedistribution head 312 is positioned with the lower end of the doorengagement bracket 360 in contact with the arm, and a slight X and/or Θmovement of the distribution head 312 is effected to move the door froma closed to an open position. The door is preferably spring-biased in aclosed position, so that that when the arm is released from contact withthe door engagement bracket 360, the door will spring back to the closedposition.

Drive wheel 334 is attached to an output shaft of drive motor 332, whichis preferably a stepper motor. A suitable motor includes Nanotec modelno. ST4118M1404-B. A rotational encoder 333 is attached to the drivemotor 332. A suitable encoder includes HEDSS model no.HKT2204-702C-200B-5E. Drive wheel 334 preferably has a diameter of 9.55mm resulting in a resolution of 0.15 mm per full motor step. The encoder333 had a resolution of 200 counts/revolution (A-B signals) resulting ina quadrupled resolution of 800 counts/revolution.

The hook actuator system 316 preferably includes a belt tensioner 346for maintaining proper tension in the belt 344. Belt tensioner 346includes a pivoting idler wheel bracket 348 to which idler wheel 336 isattached and which is pivotally attached to the side panel 315 by apivot screw 352. A slot 350 is formed in an end of the pivoting idlerwheel bracket 348, and a position lock screw 354 extends through theslot 350 into the side panel 315. A spring 356 is disposed between aportion of the pivoting idler wheel bracket 348 and the fixed idlerwheel bracket 358. Tension in the belt 344 can be adjusted by looseningthe position lock screw 354, thereby allowing the spring 356 to pivotthe pivoting idler wheel bracket 348 and thus urge the idler wheel 336upwardly to create the proper tension in the drive belt 344. When propertension is achieved in the drive belt 344, the position lock screw 354can thereafter be retightened.

The hook carriage 320 includes a rail channel 324 that translates alonga hook carriage guide rail 330 attached to an upper portion of thedistribution head frame 314. The receptacle hook 318 is attached to aninsulation mount 326 disposed between the rail channel 324 and the hook318 to electrically isolate the hook 318 from the distribution head 312to facilitate capacitive sensing of contact by the hook 318 with anotherstructural element of the analyzer 100, as will be described below.

As shown in FIG. 18, the distribution head 312 preferably includes anMRD support ledge 372 for supporting the shoulder defined by connectingstructure 164 of the MRD 160. Also, an MRD guide 370 is provided in theinterior of the distribution head frame 314 to prevent the MRD fromlifting up inside the distribution head 312.

A hook extension PCB 362 is attached to one side of the distributionhead 312 (see FIG. 17). A hook home sensor 364, preferably a slottedoptical sensor, is attached to the hook extension PCB 362. A suitablesensor includes Sharp model no. GP 1S94. The hook sensor 364 indicateswhen the hook is in the retracted, or “home,” position when a sensorflag 328 extending from the insulation mount 326 extends into theslotted optical sensor 364. The receptacle hook 318 and hook carriage320 are operatively coupled for electronic communication with theremainder of the distribution head 312 by means of a flexible cable 366attached at one end to the hook carriage 320 and at an opposite end tothe hook extension PCB 362. Strain reliefs 368 and 369 may be providedfor securing the flexible cable 366 to the distribution head frame 314and the hook carriage 320, respectively.

The automatic analyzer of the present invention includes a transferposition locating system and method adapted to automatically determine,for each receptacle-receiving structure comprising a module of theanalyzer 100, the location of the transfer position of the distributionhead 312 with respect to the receptacle-transfer portal to enable thedistribution head 312 to transfer a receptacle or group of receptacles,such as MRD 160, between the distribution head and the module.

In one embodiment, the transfer position locating method includes thesteps of moving the distribution head 312 along the transport track 458to an approximate location of one of the receptacle-receiving structures(e.g., analyzer modules) and stopping the distribution head 312 at theapproximate location and moving the distribution head 312 (or a portionthereof, e.g., hook 318) with respect to the receptacle-receivingstructure in two or more directions until a position locator elementassociated with the distribution head 312 engages a position locatorelement associated with the receptacle-receiving structure. Engagementof the position locator element associated with the distribution head312 with the position locator element associated with thereceptacle-receiving structure indicates that the distribution head 312is in a transfer position with respect to the receptacle-receivingstructure (or, alternatively, that the distribution head is at a knowndistance and direction from the transfer position) to enable thedistribution head 312 to transfer a receptacle between the distributionhead 312 and the receptacle-receiving structure. The transfer positioncoordinates for that receptacle-receiving structure are stored, and thesteps are repeated for each of the receptacle-receiving structures. Thedistribution head 312 can later be positioned with respect to eachreceptacle-receiving structure to enable the distribution head 312 totransfer a receptacle between the distribution head and thereceptacle-receiving structure by retrieving the stored transferposition coordinates associated with a receptacle-receiving structureand moving the distribution head to the retrieved transfer position.

The position locator element associated with the distribution head 312of the present invention is preferably in the form of the hook 318,which is coupled to a capacitive detection system for detecting that thehook 318 has contacted another structure. The position locator elementassociated with the receptacle-receiving structure, or analyzer module,is preferably in the form of a projection (e.g., a metal pin) extendingfrom the module at a known position with respect to the transferposition for that module. Other position locator elements may comprisehall effect sensors or optical sensors (e.g., slotted optical sensors orreflective sensors). Other optically-based position locators include acamera using image processing to find a fiducial. The position locatorelement may also be located in a known position with respect to anopening arm of a receptacle transfer portal door, so that location ofthe position locator element of a module also defines a position for thedistribution head 312 to enable the door engagement bracket 360 toengage the door opening arm of the module.

FIG. 19 shows a portion of a distribution head 312 extending areceptacle hook 318 into a receptacle portal 204 of a door assembly 214of an incubator 114. The door assembly 214 includes an actuating post220 extending from a door 216 that is slidably disposed within a doorframe 224 so as to cover the portal 204 when in the closed position. Thedoor engagement bracket 360 of the distribution head 312 engages theactuating post 220 to push the door 216 to an open position. With thedoor 216 in the open position, the receptacle hook 318 can be extendedthrough the receptacle opening 204 to insert an MRD 160 into areceptacle carrier 242 (e.g., a carousel) within the incubator 114 or toretrieve an MRD 160 from the receptacle carrier 242.

Incubator 114 further includes a locator pin 210 projecting from thedoor frame 224 adjacent the receptacle portal 204. Pin 210, located at aknown position with respect to the receptacle portal 204, functions as aposition locator element for the incubator 114. By determining andstoring the X, Z, Θ, and R coordinates at which the receptacle hook 318contacts the pin 210, those coordinates can be recalled to properlyposition and orient the receptacle carrier assembly 310 and distributionhead 312 when a receptacle needs to be placed in or removed from theincubator 114.

It should be noted that the door engagement bracket 360 shown in FIG. 19is oriented differently than the door engagement bracket 360 shown inthe other figures, such as FIG. 18, for example. In FIG. 19 the doorengagement bracket 360 extends off the right-hand side of thedistribution head 312 (when viewed in the direction of receptacle hookextension, as shown in FIG. 19) for opening the door 216 by pushing itto the right, as shown in FIG. 19. In FIG. 18, on the other hand, thedoor engagement bracket 360 extends off the left-hand side of thedistribution head 312 (when viewed in the direction of receptacle hookextension, which is opposite to the viewing direction shown in FIG. 18)for opening a door by pushing it to the left. Thus, the distributionhead 312 can be configured for opening module doors by pushing them tothe left or the right, depending on the orientation of the doorengagement bracket 360. A door engagement bracket can also be configuredto extend on both the left-hand and right-hand sides of the distributionhead 312, so that the head 312 can selectively push a door to the leftor the right, so that all module doors need not be configured to open bysliding in the same direction. In other embodiments, the door may beopened by other than lateral movement. For example, the door may open bya pivoting, hinge-wise movement, by vertical movement, up or down, or bya rotating or revolving movement. The distribution head 312 can beconfigured to engage the door and making the appropriate relativemovement to open the door.

FIG. 20 is a block diagram that schematically illustrates the controlarchitecture for the receptacle distributor 300. The controlarchitecture includes a controller 550 which communicates with andcontrols aspects of the X-translation system 500, the Z-axis drivesystem 402, the Θ-drive system 440, and the hook actuator system 316.

Controller 550 comprises a computer system for executing software thatimplements the methods and system of the current invention. Controller550 includes at least one processor, e.g., a computer, and includes datastorage memory, which may include random access memory (RAM), read onlymemory (ROM), and other types of memory known to those skilled in theart. Controller 550 may also include additional memory, including, forexample, a hard disk drive and/or a removable storage drive,representing a magnetic tape drive, an optical disk drive, USB slot,memory card interface, etc. Memory devices and storage units used hereinmay comprise any storage medium for persistent and/or volatile storageof electronic data known to or developed by persons of ordinary skill inthe art. Such data may be stored within the storage medium in adatabase, which may comprise any data structure and format known to ordeveloped by persons of ordinary skill in the art, including, forexample, a relational database, an object database, a flat file, list,and so on, or some combination thereof.

In alternative embodiments, some or all of the memory may include othersimilar means for allowing computer programs or other instructions to beloaded into a computer system. Such means can include, for example, aremovable storage unit and an interface. Examples of such can include amemory stick and memory stick interface, a secure digital card andinterface, and other portable media and interfaces which allow softwareand data to be transferred to controller 550.

The computer system of controller 550 may also include a communicationsinterface, which allows information (e.g., software, data, etc.) to betransferred between controller 550 and external devices. Examples ofcommunications interface can include a modem, a network interface (suchas an Ethernet card), a communications port, a PCMCIA slot and card, aUSB-port, a Firewire port, etc. Information transferred via acommunications interface is in the form of signals which can beelectronic, electromagnetic, optical or other signals capable of beingreceived by the communications interface.

The computer system of controller 550 can also include one or more inputdevices, such as a touch screen, stylus, keyboard, mouse or otherpointing device, microphone, and so on. Various output devices may alsobe included in the computer system, including indicator lights, adisplay, printer, and audio speakers.

In this document, terms such as “computer program medium,”“computer-readable medium,” “computer usable medium,” and the like areused to generally refer to media, such as removable storage units, ahard disk installed in hard disk drive, or signals and other means forproviding software and data to controller 550.

Computer programs (also called computer control logic) are stored in oneor more portions of the memory of controller 550. Computer programs canalso be received via a communications interface. Such computer programs,when executed, enable the computer system of controller 550 to performaspects of the present invention.

In an embodiment in which aspects of the invention are implemented usingsoftware, the software may be stored in a computer program product andloaded into the computer system of controller 550 using a removablestorage drive, a hard drive, an interface, and/or a communicationsinterface. The control logic (software), when executed by the processorof the controller 550, causes the processor to perform functionalaspects of the invention as described herein via the systems, devices,apparatuses, sensors, encoder, etc. described above. An operating systemmay perform basic tasks such as recognizing input from an input device,sending output to an output device, managing files and system resources,and managing the various processes embodying computer programs runningon the computer system.

Controller 550 may comprise a stand-alone system dedicated to thereceptacle distributor, or one or more components of controller550—e.g., processor, memory, interfaces, input/output devices, etc.—maybe a shared part of a global controller that controls one or moremodules of the analyzer 100, in addition to the receptacle distributor300.

As shown schematically in FIG. 20, with respect to the X-translationsystem 500, controller 550 receives signals from the optical encoder 503coupled to motor 502 and from home sensor 530 and sends command signalsto motor 502. With respect to the Z-axis drive system 402, controller550 receives signals from the encoder 405 (e.g., slotted disc 432)coupled to ball screw 406 and from home sensor 428 and sends commandsignals to motor 404. With respect to the Θ-drive system 440, controller550 receives signals from the encoder 441 coupled to motor 442 and fromhome sensor 450 and sends command signals to motor 442. And with respectto the hook actuator system 316, controller 550 receives signals fromthe encoder 333 coupled to motor 332, from home sensor 364, and fromcapacitive hook 318 and sends command signals to motor 332.

A process for automatically detecting the location coordinates of areceptacle transfer position with respect to the modules of the analyzer100 is represented by flow chart 600 in FIG. 21. Some or all of theprocess shown can be embodied in computer instructions stored assoftware in memory accessible by the controller 550.

In step 602, the receptacle carrier assembly 310 starts from a positionof X, Z, Θ, R=0, as communicated to the controller 550 by signalsgenerated by the home sensor 530 of the X-translation system 500, byhome sensor 428 of the Z-axis drive system 402, by home sensor 450 ofthe Θ-drive system 440, and by home sensor 364 of the hook actuatorsystem 316.

In step 604, an approximate X-coordinate location of one of the analyzermodules is retrieved from the memory of the controller 550 by thecontroller's processor, and controller 550 sends command signals tomotor 502 of the X-translation system 500 to move the carrier assembly310 along the transport track assembly 458 in the X-direction to theapproximate X-coordinate of the analyzer module. That the carrierassembly 310 is at the approximate X-coordinate can be verified by thecommand signals sent to the motor 502 (e.g., to move a specified numberof steps) and/or by signals generated by the encoder 503.

In step 606, controller 550 commands motor 442 of the Θ-drive system 440to rotate the distribution head 312, to an orientation of approximately90 degrees so that the receptacle opening of the distribution head 312faces the module. That the carrier assembly 310 is in the desiredrotational orientation can be verified by the command signals sent tothe motor 442 (e.g., to move a specified number of steps) and/or bysignals generated by the encoder 441.

In step 608, controller 550 commands motor 404 of the Z-axis drivesystem 402 to move the distribution head 312 upwardly in the +Z-axisdirection a specified distance (of, e.g., 5 mm to an absolute positionof Z=+5 mm) That the carrier assembly 310 has moved the proper distancealong the Z-axis can be verified by the command signals sent to themotor 404 (e.g., to move a specified number of steps) and/or by signalsgenerated by the encoder 405.

In step 610, controller 550 commands motor 332 of the hook actuatorsystem 316 to extend the hook 318 to a theoretical position of aposition locator element (e.g., a pin or other projection extending fromthe module at a known position relative to the receptacle transferposition for that module). The theoretical position can be attained bymoving the hook 318 a specified distance (e.g., 2 mm) toward the module,or, if the theoretical position varies significantly from module tomodule, the coordinates of the theoretical position can stored in thecontroller's memory and retrieved when necessary by the processor of thecontroller 550. That the hook 318 has extended to the desired positioncan be verified by the command signals sent to the motor 332 (e.g., tomove a specified number of steps) and/or by signals generated by theencoder 333.

In step 612, controller 550 commands the motor 502 of the X-translationsystem 500 to move the receptacle carrier assembly 310 step-by-step inthe X-axis towards the expected location of the position locator elementuntil the hook 318 makes contact with the position locator element asdetected by capacitive sensing and communicated to the controller 550.Controller 550 commands motor 502 to stop X-translation, and, in step614, the X-coordinate of the contact, as determined by signals generatedby the encoder 503 of the X-translation system 500, is stored in thememory of controller 550.

In step 616, controller 550 commands motor 332 of the hook actuatorsystem 316 to retract the hook 318 into the distribution head 312.

In step 618, controller 550 commands motor 404 of the Z-axis drivesystem 402 to move the distribution head 312 downwardly in the −Z-axisdirection to location known to be below the theoretical position of theposition locator element. The distribution head can be moved a specifieddistance (e.g., a distance of 13 mm to an absolute Z=−8 mm), or, if thetheoretical position varies significantly from module to module, thecoordinates of the theoretical position can stored in the controller'smemory and retrieved when necessary by the processor of the controller550. The Z coordinate location of the distribution head is determined bysignals generated by the encoder 405.

In step 620, the controller 550, using the stored results of steps 612and 614, commands motor 502 of the X-translation system 500 to move thereceptacle carrier assembly 310 in the X-direction to center the hook618 with respect to the position locator element. This is accomplishedby moving the receptacle carrier assembly 310 in the X-direction by adistance corresponding to half the width of the position locator elementfrom the contact X-coordinate determined and stored in steps 612 and614.

In step 622, controller 550 commands motor 332 of the hook actuatorsystem 316 to extend the hook 318 to a theoretical position of theposition locator element. Again, the theoretical position can beattained by moving the hook 318 a specified distance (e.g., 2 mm) towardthe module, or, if the theoretical position varies significantly frommodule to module, the coordinates of the theoretical position can storedin the controller's memory and retrieved when necessary by the processorof the controller 550.

In step 624, controller 550 commands motor 404 of the Z-axis drivesystem 402 to move the receptacle distribution head 312 in the +Z-axisdirection towards the expected location of the position locator elementuntil the hook 318 makes contact with the position locator element asdetected by capacitive sensing and communicated to the controller 550.Controller 550 commands motor 404 to stop Z-axis drive, and, in step626, the Z-coordinate of the contact, as determined by signals generatedby the encoder 405 of the Z-axis drive system 402, is stored in thememory of controller 550.

In step 628, controller 550 commands motor 332 of the hook actuatorsystem 316 to retract the hook 318 into the distribution head 312.

In step 630, the controller 550, using the stored results of steps 624and 626, commands motor 404 of the Z-axis drive system 402 to move thedistribution head 312 in the Z-direction to center the hook 618 withrespect to the position locator element.

In step 632, controller 550 commands motor 332 of the hook actuatorsystem 316 to move the hook 318, in the R-direction, toward the positionlocator element until hook 318 makes contact with the position locatorelement as detected by capacitive sensing and communicated to thecontroller 550. Controller 550 commands motor 332 to stop hookextension, and, in step 634, the R-coordinate of the contact, asdetermined by signals generated by encoder 333 of the hook actuatorsystem 316, is stored in the memory of controller 550.

In step 636, this procedure (at least steps 604-634) is repeated for allmodules, and the receptacle transfer coordinates of each are stored.Thus, when the receptacle distributor 300 is required to transfer areceptacle into or out of a receptacle receiving structure (i.e.,module), the X and Z coordinates of the receptacle transfer position forthat module are retrieved by the controller 550, and the X-translationsystem 500 and the Z-axis drive system 402 are commanded by thecontroller to position the distribution head 312 at the proper X and Zcoordinates, respectively. Similarly, the R-coordinate for thereceptacle transfer position is retrieved by the controller 550, whichuses the information to effect proper extension of hook 318 via hookactuator system 316 for placing the receptacle into the module orremoving the receptacle from the module.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but, on the contrary, it is intended to covervarious modifications and equivalent arrangements included within thespirit and scope of the appended claims. Thus, it is to be understoodthat variations in the particular parameters used in defining thepresent invention can be made without departing from the novel aspectsof this invention as defined in the following claims.

The invention claimed is:
 1. An apparatus for transferring one or morereceptacles between a plurality of receptacle-receiving structurescomprising: a transport track having opposed ends, wherein thereceptacle-receiving structures are disposed at different locationsadjacent to said transport track; a receptacle carrier operativelyengaged with said transport track and adapted to carry a receptacle andtranslate along said transport track in a first or second directionbetween said opposed ends, wherein said receptacle carrier is furtheradapted to selectively stop at a transfer position with respect to anyof the receptacle-receiving structures disposed adjacent said transporttrack, and wherein said receptacle carrier includes a receptacle movingmechanism adapted to move a receptacle with respect to said receptaclecarrier to move a receptacle into said receptacle carrier, move areceptacle out of said receptacle carrier, or alternately move areceptacle into and out of said receptacle carrier; a transfer positionlocating system adapted to automatically determine, for eachreceptacle-receiving structure, a location of a transfer position of thereceptacle carrier with respect to the receptacle-receiving structure toenable the receptacle carrier to transfer a receptacle between thereceptacle carrier and the receptacle-receiving structure; and a carrierelevation system adapted to move at least a portion of said receptaclecarrier in a transverse direction with respect to said transport track.2. The apparatus of claim 1, wherein said transport track comprises abase portion and an upright backing portion and a guide track mounted onsaid base portion and a guide rail mounted to said upright portion,wherein a portion of said receptacle carrier is engaged with said guidetrack and said guide rail.
 3. The apparatus of claim 1, wherein saidtransport track is linear.
 4. The apparatus of claim 1, wherein saidtransport track is substantially horizontal.
 5. The apparatus of claim1, further comprising a carrier translation system adapted to effectpowered translation of said receptacle carrier along said transporttrack.
 6. The apparatus of claim 5, wherein said carrier translationsystem comprises: a translation drive motor having an output shaft; acarrier drive belt coupled to said receptacle carrier; and one or morepulleys supporting said carrier drive belt, wherein said carrier drivebelt is coupled to said output shaft of said translation drive motor sothat rotation of said output shaft is transmitted via said carrier drivebelt into translation of said receptacle carrier along said transporttrack.
 7. The apparatus of claim 6, further comprising an encodercoupled to said translation drive motor for monitoring rotations of saidoutput shaft.
 8. The apparatus of claim 6, further comprising a belttensioner configured to impart tension in said carrier drive belt. 9.The apparatus of claim 1, further comprising a carrier position sensorconfigured to detect when said receptacle carrier is in a specifiedposition on said transport track.
 10. The apparatus of claim 1, whereinsaid transport track is substantially horizontal and wherein saidcarrier elevation system is adapted to move at least a portion of saidreceptacle carrier in a vertical direction with respect to saidtransport track.
 11. The apparatus of claim 1, wherein said carrierelevation system comprises: an elevation drive motor having an outputshaft; a drive screw shaft having a longitudinal axis and operativelycoupled to said elevation drive motor for powered rotation of said drivescrew shaft; and an elevation block coupled to said drive screw shaftsuch that rotation of said drive screw shaft causes translation of saidelevation block along the longitudinal axis of said drive screw shaft,wherein at least a portion of said receptacle carrier is carried on saidelevation block.
 12. The apparatus of claim 11, further comprising anencoder coupled to said elevation drive motor for monitoring rotationsof said output shaft.
 13. The apparatus of claim 1, further comprising aelevation position sensor configured to detect when at least a portionof said receptacle carrier is in a specified transverse distance fromsaid transport track.
 14. The apparatus of claim 1, further comprising acarrier rotation system adapted to rotate at least a portion of saidreceptacle carrier about an axis of rotation.
 15. The apparatus of claimof claim 14, wherein said transport track is substantially horizontaland wherein said axis of rotation is substantially vertical.
 16. Theapparatus of claim 14, wherein said carrier rotation system comprises: arotation drive motor having an output shaft; a drive gear coupled tosaid output shaft; and a platform gear mounted so as to be rotatableabout said axis of rotation and coupled to said drive gear for poweredrotation to said platform gear, wherein at least a portion of saidreceptacle carrier is carried on said platform gear.
 17. The apparatusof claim 16, further comprising an encoder coupled to said rotationdrive motor for monitoring rotations of said output shaft.
 18. Theapparatus of claim 14, further comprising a rotation position sensorconfigured to detect when at least a portion of said receptacle carrieris in a specified rotational position about said axis of rotation. 19.The apparatus of claim 1, wherein said receptacle moving mechanismcomprises: a receptacle engagement device configured to releasablyengage a receptacle to permit physical manipulation of the engagedreceptacle; and a receptacle drive motor having an output shaft coupledto said receptacle engagement device for effecting powered movement ofsaid receptacle engagement device.
 20. The apparatus of claim 19,wherein said receptacle engagement device comprises a hook.
 21. Theapparatus of claim 19, wherein said receptacle engagement device iscarried on an engagement device carriage, and wherein said receptaclemoving mechanism further comprises: a receptacle guide rail on whichsaid engagement device carriage is translatably carried; a receptacledrive belt coupled to said engagement device carriage; and one or morepulleys supporting said receptacle drive belt, wherein said receptacledrive belt is coupled to said output shaft of said receptacle drivemotor so that rotation of said output shaft is transmitted via saidreceptacle drive belt into translation of said engagement devicecarriage along said receptacle guide rail.
 22. The apparatus of claim19, further comprising an encoder coupled to said receptacle drive motorfor monitoring rotations of said output shaft.
 23. The apparatus ofclaim 21, further comprising a belt tensioner configured to imparttension to said receptacle drive belt.
 24. The apparatus of claim 21,further comprising an engagement device position sensor configured todetect when said engagement device carriage is in a specified positionon said receptacle guide rail.
 25. The apparatus of claim 1, whereinsaid receptacle carrier comprises: a receptacle carrier carriage adaptedto translate along said transport track; and a distribution headsupported by said receptacle carrier carriage and configured to receiveand hold a receptacle and wherein said receptacle moving mechanism isdisposed within said distribution head.
 26. The apparatus of claim 25,further comprising a carrier translation system coupled to saidreceptacle carrier carriage and adapted to effect powered translation ofsaid receptacle carrier carriage along said transport track.
 27. Theapparatus of claim 25, wherein the carrier elevation system is coupledto said distribution head and adapted to move said distribution headrelative to said receptacle carrier carriage in a direction transverseto said transport track.
 28. The apparatus of claim 25, wherein thecarrier rotation system is coupled to said distribution head and adaptedto rotate said distribution head relative to said receptacle carriercarriage about an axis of rotation.
 29. The apparatus of claim 1,wherein said transfer position locating system comprises: a positionlocator element associated with said receptacle carrier; one or moresignal generators adapted to generate signal data representative of atleast one of a position and an orientation of said receptacle carrier;and data storage configured to store signal data from said one or moresignal generators when said position locator element associated withsaid receptacle carrier engages a position locator element associatedwith the receptacle-receiving structure.
 30. The apparatus of claim 29,wherein said position locator element associated with said receptaclecarrier comprises a portion of the receptacle carrier that physicallycontacts a position locator element associated with thereceptacle-receiving structure.
 31. The apparatus of claim 29, whereinsaid position locator element associated with said receptacle carriercomprises a receptacle engagement device coupled with said receptaclemoving mechanism and configured to releasably engage a receptacle topermit physical manipulation of the engaged receptacle.
 32. Theapparatus of claim 31, further comprising a controller in signalcommunication with said receptacle engagement device to capacitivelysense when the receptacle engagement device contacts the positionlocator element associated with the receptacle-receiving structure. 33.A method for transferring one or more receptacles between a plurality ofreceptacle receiving structures in an automated apparatus comprising areceptacle carriage, a plurality of receptacle-receiving structures, anda transport track, said method comprising the steps of: (a) moving thereceptacle carriage along the track to an approximate location of one ofthe receptacle-receiving structures; (b) moving the receptacle carriagewith respect to the receptacle-receiving structure in two or moredirections until a position locator element associated with thereceptacle carriage engages a position locator element associated withthe receptacle-receiving structure, wherein engagement of the positionlocator element associated with the receptacle carriage with theposition locator element associated with the receptacle-receivingstructure identifies a transfer position of the receptacle carriage withrespect to the receptacle-receiving structure to enable the receptaclecarriage to transfer a receptacle between the receptacle carriage andthe receptacle-receiving structure; (c) storing data relating to thetransfer position for the receptacle-receiving structure; (d) repeatingsteps (a)-(c) for each of the receptacle-receiving structures; and (e)positioning the receptacle carriage with respect to eachreceptacle-receiving structure to enable the receptacle carriage totransfer a receptacle between the receptacle carriage and thereceptacle-receiving structure by retrieving the stored transferposition data associated with a receptacle-receiving structure andmoving the receptacle carriage to the transfer position defined by theretrieved transfer position data.
 34. The method of claim 33, whereinmoving the receptacle carriage with respect to the receptacle-receivingstructure in two or more directions comprises moving the receptaclecarriage along the track and moving the receptacle carriage in at leastone direction transverse to the direction of the track.
 35. The methodof claim 33, wherein moving the receptacle carriage with respect to thereceptacle-receiving structure in two or more directions furthercomprises rotating the receptacle carriage about an axis of rotation andmoving a receptacle-engaging element of the receptacle carriage in aradial direction with respect to the axis of rotation.
 36. The method ofclaim 33, wherein moving the receptacle carriage with respect to thereceptacle-receiving structure until a position locator elementassociated with the receptacle carriage engages a position locatorelement associated with the receptacle-receiving structure comprisesmoving the receptacle carriage with respect to the receptacle-receivingstructure until a portion of the receptacle carriage physically contactsa portion of the receptacle-receiving structure.
 37. The method of claim36, wherein physical contact of a portion of the receptacle carriagewith a portion of the receptacle-receiving structure is determined bycapacitive sensing.
 38. An apparatus for transferring one or morereceptacles between a plurality of receptacle-receiving structures, oneor more of the receptacle receiving structures including a receptacletransfer portal through which a receptacle is placed into or removedfrom the receptacle-receiving structure and a door disposed over thereceptacle transfer portal, said apparatus comprising: a receptaclecarriage adapted to carry a receptacle and to selectively stop at atransfer position with respect to any of a plurality ofreceptacle-receiving structures, one or more of the receptacle receivingstructures including a receptacle transfer portal, and wherein saidreceptacle carriage includes a receptacle moving mechanism adapted tomove a receptacle with respect to said receptacle carriage to move areceptacle into said receptacle carriage, move a receptacle out of saidreceptacle carriage, or alternately move a receptacle into and out ofsaid receptacle carriage, wherein a portion of said receptacle carriageis adapted to engage a door of a receptacle-receiving structure and toopen the door upon performance of a predetermined movement of saidreceptacle carriage with respect to the receptacle-receiving structure;and a carriage positioning system adapted to automatically position saidreceptacle carriage so that a portion of said receptacle carriageengages a door of a selected one of the receptacle-receiving structuresand to effect the predetermined movement of said receptacle carriage toopen the door.
 39. The apparatus of claim 38, further comprising atransfer position locating system adapted to automatically determine,for each receptacle-receiving structure, a location of a transferposition of the receptacle carriage with respect to thereceptacle-receiving structure to enable the receptacle carriage toengage a door of each receptacle-receiving structure.
 40. The apparatusof claim 39, wherein said transfer position locating system comprises: aposition locator element associated with said receptacle carriage; oneor more signal generators adapted to generate signal data representativeof at least one of a position and an orientation of said receptaclecarriage; and data storage configured to store signal data from said oneor more signal generators when said position locator element associatedwith said receptacle carriage engages a position locator elementassociated with the receptacle-receiving structure.
 41. The apparatus ofclaim 38, wherein the portion of said receptacle carriage adapted toengage the door of the receptacle-receiving structure comprises abracket projecting from said receptacle carriage and configured toengage by contact an actuating element extending from the door.
 42. Theapparatus of claim 38, wherein a portion of said receptacle carriage isadapted to engage a door of a receptacle-receiving structure and to openthe door upon performance of a lateral movement of said receptaclecarriage to move the door laterally from a closed position to an openposition with respect to the receptacle transport portal.
 43. Theapparatus of claim 38, wherein a portion of said receptacle carriage isadapted to remain engaged with the door of the receptacle-receivingstructure after the predetermined movement of said receptacle carriageto hold the door in an open position with respect to the receptacletransport portal while the receptacle carriage moves a receptaclethrough the receptacle transport portal.
 44. A method of opening a doorin an automated apparatus comprising a plurality of receptacle receivingstructures and a receptacle carriage, wherein one or more of thereceptacle receiving structures includes a receptacle transfer portalthrough which a receptacle is placed into or removed from thereceptacle-receiving structure and a door disposed over the receptacletransfer portal, said method comprising the steps of: positioning thereceptacle carriage so that a portion of the receptacle carriage adaptedto engage a door of a receptacle-receiving structure and to open thedoor upon performance of a predetermined movement of the receptaclecarriage with respect to the receptacle-receiving structure engages adoor of a selected one of the receptacle-receiving structures; andeffecting the predetermined movement of the receptacle carriage to openthe door.
 45. The method of claim 44, wherein positioning the receptaclecarriage comprises the steps of: (a) moving the receptacle carriage toan approximate location of one of the receptacle-receiving structures;(b) moving the receptacle carriage with respect to thereceptacle-receiving structure in two or more directions until aposition locator element associated with the receptacle carriage engagesa position locator element associated with the receptacle-receivingstructure, wherein engagement of the position locator element associatedwith the receptacle carriage with the position locator elementassociated with the receptacle-receiving structure identifies a transferposition of the receptacle carriage with respect to thereceptacle-receiving structure to enable the receptacle carriage toengage a door of the receptacle-receiving structure; (c) storing datarelating to the transfer position for the receptacle-receivingstructure; (d) repeating steps (a)-(c) for each of thereceptacle-receiving structures; and (e) positioning the receptaclecarriage with respect to each receptacle-receiving structure to enablethe receptacle carriage to engage the door of each receptacle carriageby retrieving the stored transfer position data associated with areceptacle-receiving structure and moving the receptacle carriage to thetransfer position defined by the retrieved transfer position data. 46.The method of claim 44, wherein the portion of the receptacle carriageadapted to engage the door of the receptacle-receiving structurecomprises a bracket projecting from the receptacle carriage andconfigured to engage by contact an actuating element extending from thedoor, and positioning the receptacle carriage comprises moving thereceptacle carriage to a position at which the bracket engages theactuating element of the door.
 47. The method of claim 44, whereineffecting the predetermined movement comprises moving the receptaclecarriage laterally to move the door laterally from a closed position toan open position with respect to the receptacle transport portal. 48.The method of claim 44, further comprising, after effecting thepredetermined movement, maintaining a position of the receptaclecarriage engaged with the door of the receptacle-receiving structure tohold the door in an open position with respect to the receptacletransport portal while the receptacle carriage moves a receptaclethrough the receptacle transport portal.